EP3713698B1 - Slm system and method for operating the slm system - Google Patents
Slm system and method for operating the slm system Download PDFInfo
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- EP3713698B1 EP3713698B1 EP19704201.3A EP19704201A EP3713698B1 EP 3713698 B1 EP3713698 B1 EP 3713698B1 EP 19704201 A EP19704201 A EP 19704201A EP 3713698 B1 EP3713698 B1 EP 3713698B1
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- 230000005855 radiation Effects 0.000 claims description 90
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- 238000002844 melting Methods 0.000 claims description 10
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/141—Processes of additive manufacturing using only solid materials
- B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/36—Process control of energy beam parameters
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/08—Devices involving relative movement between laser beam and workpiece
- B23K26/082—Scanning systems, i.e. devices involving movement of the laser beam relative to the laser head
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C64/264—Arrangements for irradiation
- B29C64/268—Arrangements for irradiation using laser beams; using electron beams [EB]
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C64/264—Arrangements for irradiation
- B29C64/286—Optical filters, e.g. masks
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/30—Auxiliary operations or equipment
- B29C64/386—Data acquisition or data processing for additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/30—Auxiliary operations or equipment
- B29C64/386—Data acquisition or data processing for additive manufacturing
- B29C64/393—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y50/00—Data acquisition or data processing for additive manufacturing
- B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/36—Process control of energy beam parameters
- B22F10/366—Scanning parameters, e.g. hatch distance or scanning strategy
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/40—Radiation means
- B22F12/41—Radiation means characterised by the type, e.g. laser or electron beam
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/40—Radiation means
- B22F12/44—Radiation means characterised by the configuration of the radiation means
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/90—Means for process control, e.g. cameras or sensors
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y50/00—Data acquisition or data processing for additive manufacturing
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Definitions
- An SLM system is a system in which a component is built up layer by layer through selective laser melting (SLM) of a powder.
- SLM selective laser melting
- hybrid selective laser melting can be used.
- a section of the component is manufactured using a different manufacturing process, such as casting.
- One section is then introduced into the SLM system and another section of the component is applied to the one section using selective laser melting. So that one section and the other section fit together as accurately as possible, it would be desirable to determine as precisely as possible where one section is located in the SLM system.
- document DE102007056984A1 discloses a method for producing a three-dimensional object by laser sintering, in which the object is formed by solidifying a powdery material layer by layer at the locations of the respective layer corresponding to the object by means of the action of laser radiation, an IR radiation image being recorded in an applied powder layer, wherein Using the IR radiation image, defects and/or geometric unevenness in the applied powder layer can be determined.
- the object of the invention is therefore to create an SLM system and a method for operating the SLM system, with which it is possible to determine with the highest possible accuracy where a component is located in the SLM system.
- the method according to the invention for operating an SLM system has the steps: a) Providing an installation space in the SLM system, which has a component and a powder adjacent thereto, with an upward-facing surface of the installation space being areas formed by the component and has other areas formed by the powder; b) scanning the upward-facing surface with laser radiation, the power and duration of which are chosen such that the component and the powder are not melted; c) detecting radiation that arises due to an interaction of the laser radiation with the installation space; d) Inferring a position and dimensions of the component from the radiation detected in step c).
- the method according to the invention it is possible to determine the position and dimensions of the component with a particularly high level of accuracy.
- the same laser source can be used in step b) as in subsequent selective laser melting, so that a conventional SLM system can be retrofitted cost-effectively to carry out the method according to the invention.
- the power and the duration of exposure of the laser radiation depends on many properties of the component and the powder, such as a surface quality, an absorption capacity for the laser radiation, a thermal conductivity, a particle size distribution and a packing density of the powder. These properties can vary greatly with different materials. However, it is possible without any problem and without much effort to carry out experiments in which the power of the laser radiation and/or the duration of exposure to the laser radiation are varied so long that neither the component nor the powder is melted and at the same time there is sufficient radiation in step c). it is detected that the position and dimensions of the component can be determined.
- the interaction can be, for example, a reflection and/or a scattering on the upward-facing surface of the installation space. This means that in step c) laser radiation reflected and/or scattered by the upward-facing surface of the installation space is measured.
- the interaction can also involve, for example, a heating of the installation space, which means that the laser radiation is at least partially absorbed by the installation space and, according to the invention, in step c) a thermal radiation emitted by the installation space is measured.
- the method comprises the step: e) identifying, based on the dimensions, the surface of the component arranged in the upward-facing surface of the installation space in a three-dimensional computer model that contains the component.
- the method has the step: f) applying at least one layer of the powder to the upward-facing surface of the installation space and expanding the component by selective laser melting of the powder using laser radiation in each of the layers based on the position and the area identified in the three-dimensional computer model .
- step a) a section of the component is provided and in step f) another section of the component is completed by selective laser melting.
- step f) it is advantageously achieved that in step f) exactly that part of the computer model is produced that is not formed by one section, and thus that one section and the section fit together particularly well. For example, manufacturing tolerances in the production of one section can be compensated for. It is also possible to produce the component free of edges and/or burrs.
- the same laser source is used to generate the laser radiation in steps b) and f).
- an identical or at least very similar grid is used when inferring the position and dimensions of the component and during selective laser melting, so that one section and the other section in the component fit together particularly well.
- the radiation is thermal radiation.
- the thermal radiation has the advantage that it is emitted evenly in all directions, so there is great flexibility as to where in the SLM system a detector can be arranged to detect the thermal radiation.
- the thermal radiation is preferably detected at a detection wavelength that is different from the wavelength of the laser radiation. This can advantageously avoid the laser radiation being detected in step c), which can falsify the conclusions about the position and dimensions of the component in step d).
- step c) that part of the radiation is preferably detected which, starting from an impact point of the laser radiation arranged on the upward-facing surface of the installation space, propagates counter to the direction of the laser radiation.
- the advantage here is an easy-to-adjust structure.
- the radiation can be separated from the laser radiation using a beam splitter.
- step c) it is preferred that in step c) that part of the radiation is detected which, starting from an impact point of the laser radiation arranged on the upward-facing surface of the installation space, propagates offset from the direction of the laser radiation.
- the amount of laser radiation that is detected together with the radiation in step c) and which can falsify the conclusions about the position and dimensions of the component in step d) can be advantageously reduced.
- a grid is formed from intensities of radiation detected in step c) and transitions from the regions to the other regions are determined by identifying gradients of the intensities in the grid.
- the transition from the areas formed by the component to the other areas formed by the powder are accompanied by a reduction in the detected intensity or an increase in the detected intensity.
- the grid is first scanned with a coarse mesh and after determining the transitions in step d) the grid is scanned with a fine mesh in the area of the transitions.
- the areas and the other areas preferably lie in the same horizontal plane, in particular the areas and the other areas lie completely in the same horizontal plane.
- the SLM system according to the invention is set up to carry out the steps of the method according to the invention or according to a preferred method.
- an installation space 17 was provided in an SLM system 1 in step a).
- the installation space 17 has a component 2 and a powder 3 adjacent to it.
- An upward-facing surface 18 of the installation space 17 has areas that are formed by the component 2 and other areas that are formed by the powder 3. The areas and the other areas lie completely in the same horizontal plane.
- the component 2 can be produced by a manufacturing process other than a generative manufacturing process, in particular selective laser melting, for example by casting.
- the powder 3 can be, for example, a metal powder and/or a ceramic powder.
- the SLM system 1 also has a laser source 4, which is set up to emit laser radiation.
- the laser source 4 can be, for example, an Nd:YAG laser.
- the laser radiation can be formed by the fundamental of the Nd:YAG laser and thus a Have a wavelength of 1064 nm.
- the laser radiation propagates along a beam path 5 during operation of the SLM system 1.
- the SLM system 1 has a beam splitter 6, a scanning mirror 7 and a lens system 8. How it looks Figure 1 As can be seen, the SLM system 1 is set up to direct the laser radiation via the beam splitter 6 onto the scanning mirror 7.
- the scanning mirror 7 is movably mounted and can be controlled by the SLM system 1 in such a way that the laser radiation is directed to any point via the lens system 8, which is arranged in the beam path 5 between the scanning mirror 7 and the upward-facing surface 18 of the installation space 17 the upward-facing surface 18 of the installation space 17 can be steered.
- the lens system 18 is set up to focus the laser radiation on the upward-facing surface 18 of the installation space 17.
- the lens system 18 is, for example, an F-theta lens.
- the upward-facing surface 18 is scanned with the laser radiation, the power and the duration of exposure of the laser radiation being selected such that the component 2 and the powder 3 are not melted.
- the power and the duration of exposure of the laser radiation are selected such that the component 2 and the powder 3 are warmed up.
- the laser source 4 is an Nd:YAG laser
- the power can be varied by varying the light power with which an Nd:YAG crystal of the Nd:YAG laser is pumped. Due to an interaction of the laser radiation with the installation space 17 at an impact point 9 of the laser radiation, which is arranged on the upward-facing surface 18 of the installation space 17, thermal radiation 10 is emitted.
- the thermal radiation is detected.
- the thermal radiation can be detected at a detection wavelength that is different from the wavelength of the laser radiation.
- the detection wavelength can be longer than 1064 nm.
- This can be done, for example, by means of a detector 13 or by means of a Camera 14 done.
- the detector 13 it is sufficient if it only has a single detector element, such as a photodiode.
- the camera 14, on the other hand, has a two-dimensional matrix of detector elements.
- the camera 14 can be, for example, a CMOS camera or a microbolometer camera.
- the camera 14 has a lens 15 which is set up to image the upward-facing surface 18 of the installation space 17 onto the two-dimensional matrix on the detector elements.
- the imaging errors that arise due to an oblique alignment of the camera 14 on the upward-facing surface 18 of the installation space 17 can be corrected, for example, by using a Scheimpflug lens for the lens 15.
- Figure 1 shows that the detector 13 is arranged to detect the thermal radiation reflected on the beam splitter 6. It is also conceivable that the detector 13 is arranged at a different position in the SLM system, as long as the field of view of the detector 13 includes the entire upward-facing surface 18 of the installation space 17. Detecting the thermal radiation reflected by the beam splitter 6 has the advantage that the lens system 8 collects a larger amount of infrared radiation and directs it to the detector 13 than if the detector 13 is arranged at the other position.
- Figure 1 shows a first beam path 11 of the thermal radiation 10, which describes that part of the thermal radiation which, starting from the point of impact 9 of the laser radiation, propagates against the direction of the laser radiation.
- a second beam path 12 of the thermal radiation 10 which detects that part of the thermal radiation which, starting from the point of impact 9 of the laser radiation, spreads offset from the direction of the laser radiation. It is conceivable that in step c) the heat radiation from only the beam path 11, from only the beam path 12 or from both beam paths 11 and 12 is detected.
- the first beam path 10 can also have the laser radiation.
- the laser radiation in the first beam path 10 may have been reflected back by the lens system 8 and incompletely separated from the thermal radiation 10 at the beam splitter 6. This incompletely separated laser radiation can interfere with the detection of thermal radiation.
- a step d the position and dimensions of the component 2 are deduced from the heat radiation detected in step c).
- a grid 16 of radiation intensities detected in step c) is formed and transitions from the areas to the other areas are determined by identifying gradients of the intensities in the grid 16.
- the grid 16 is spanned in the x direction and in the y direction.
- Figure 1 The x-direction, the y-direction and also a z-direction are also shown. It is conceivable that in step c) the grid 16 is first scanned with a coarse mesh and, after determining the transitions in step d), the grid 16 is scanned with a fine mesh in the area of the transitions.
- a step e) the surface of the component 2 arranged in the upward-facing surface 18 of the installation space 17 is identified in a three-dimensional computer model 19, which contains the component 2, based on the dimensions.
- the computer model 19 is in Figure 1 illustrates and has a dashed section of the component 2, which is one section of the component 2, and a hatched section of the component 2, which is the other section of the component 2.
- a step f) at least one layer of the powder 3 is applied to the upward-facing surface 18 of the construction space 17 and the component 2 is expanded by selective laser melting of the powder 3 using laser radiation in each of the layers based on the position and the area identified in the three-dimensional computer model 19. This is particularly relevant if the cross section of component 2, as in Figure 1 shown varies in the z direction.
- steps b) and f) can, as in Figure 1 shown, the same laser source 4 can be used to generate the laser radiation.
Description
Bei einer SLM-Anlage handelt es sich um eine Anlage, bei der durch selektives Laserschmelzen (englisch: selective laser melting, SLM) eines Pulvers ein Bauteil schichtweise aufgebaut wird. Bei großen Bauteilen kann ein sogenanntes hybrides selektives Laserschmelzen zum Einsatz kommen. Dabei wird zuerst ein Abschnitt des Bauteils durch ein anderes Herstellungsverfahren, wie beispielsweise durch Gießen, hergestellt. Anschließend wird der eine Abschnitt in die SLM-Anlage eingebracht und ein anderer Abschnitt des Bauteils durch das selektive Laserschmelzen auf den einen Abschnitt aufgebracht. Damit der eine Abschnitt und der andere Abschnitt möglichst genau aufeinanderpassen, wäre es wünschenswert, möglichst genau zu bestimmen, wo sich der eine Abschnitt in der SLM-Anlage befindet.An SLM system is a system in which a component is built up layer by layer through selective laser melting (SLM) of a powder. For large components, so-called hybrid selective laser melting can be used. First, a section of the component is manufactured using a different manufacturing process, such as casting. One section is then introduced into the SLM system and another section of the component is applied to the one section using selective laser melting. So that one section and the other section fit together as accurately as possible, it would be desirable to determine as precisely as possible where one section is located in the SLM system.
Dokument
Aufgabe der Erfindung ist es daher eine SLM-Anlage und ein Verfahren zum Betreiben der SLM-Anlage zu schaffen, mit denen mit einer möglichst hohen Genauigkeit bestimmbar ist, wo sich ein Bauteil in der SLM-Anlage befindet.The object of the invention is therefore to create an SLM system and a method for operating the SLM system, with which it is possible to determine with the highest possible accuracy where a component is located in the SLM system.
Die vorliegende Erfindung wird durch die unabhängigen Ansprüche definiert. Vorteilhafte Ausgestaltungen der Erfindung sind in den abhängigen Ansprüchen definiert.The present invention is defined by the independent claims. Advantageous embodiments of the invention are defined in the dependent claims.
Das erfindungsgemäße Verfahren zum Betreiben einer SLM-Anlage weist die Schritte auf: a) Bereitstellen eines Bauraums in der SLM-Anlage, der ein Bauteil und daran angrenzend ein Pulver aufweist, wobei eine nach oben gewandte Oberfläche des Bauraums Bereiche, die von dem Bauteil gebildet sind, und andere Bereiche aufweist, die von dem Pulver gebildet sind; b) Abrastern der nach oben gewandten Oberfläche mit Laserstrahlung, deren Leistung und Einwirkungsdauer derart gewählt werden, dass das Bauteil und das Pulver nicht geschmolzen werden; c) Detektieren von Strahlung, die aufgrund einer Wechselwirkung der Laserstrahlung mit dem Bauraum entsteht; d) Rückschließen von der in Schritt c) detektierten Strahlung auf eine Position und Abmessungen des Bauteils.The method according to the invention for operating an SLM system has the steps: a) Providing an installation space in the SLM system, which has a component and a powder adjacent thereto, with an upward-facing surface of the installation space being areas formed by the component and has other areas formed by the powder; b) scanning the upward-facing surface with laser radiation, the power and duration of which are chosen such that the component and the powder are not melted; c) detecting radiation that arises due to an interaction of the laser radiation with the installation space; d) Inferring a position and dimensions of the component from the radiation detected in step c).
Mit dem erfindungsgemäßen Verfahren ist es möglich, die Position und die Abmessungen des Bauteils mit einer besonders hohen Genauigkeit zu bestimmen. Zudem kann in Schritt b) die gleiche Laserquelle wie bei einem anschließenden selektiven Laserschmelzen verwendet werden, so dass eine herkömmliche SLM-Anlage kostengünstig zum Durchführen des erfindungsgemäßen Verfahrens nachrüstbar ist.With the method according to the invention it is possible to determine the position and dimensions of the component with a particularly high level of accuracy. In addition, the same laser source can be used in step b) as in subsequent selective laser melting, so that a conventional SLM system can be retrofitted cost-effectively to carry out the method according to the invention.
Wie hoch die Leistung und die Einwirkungsdauer der Laserstrahlung zu wählen ist, hängt von vielen Eigenschaften des Bauteils und des Pulvers ab, wie beispielsweise von einer Oberflächenbeschaffenheit, von einer Absorptionsfähigkeit für die Laserstrahlung, von einer Wärmeleitfähigkeit, von einer Partikelgrößenverteilung und einer Packungsdichte des Pulvers. Diese Eigenschaften können sehr stark bei unterschiedlichen Materialien variieren. Jedoch ist es problemlos und ohne großen Aufwand möglich, Versuche durchzuführen, bei denen die Leistung der Laserstrahlung und/oder die Einwirkungsdauer der Laserstrahlung so lange variiert werden, das weder das Bauteil noch das Pulver geschmolzen werden und gleichzeitig in Schritt c) ausreichend von der Strahlung detektiert wird, dass die Position und die Abmessungen des Bauteils bestimmbar sind.How high the power and the duration of exposure of the laser radiation should be selected depends on many properties of the component and the powder, such as a surface quality, an absorption capacity for the laser radiation, a thermal conductivity, a particle size distribution and a packing density of the powder. These properties can vary greatly with different materials. However, it is possible without any problem and without much effort to carry out experiments in which the power of the laser radiation and/or the duration of exposure to the laser radiation are varied so long that neither the component nor the powder is melted and at the same time there is sufficient radiation in step c). it is detected that the position and dimensions of the component can be determined.
Bei der Wechselwirkung kann es sich beispielsweise um eine Reflektion und/oder um eine Streuung an der nach oben gewandten Oberfläche des Bauraums handeln. Dies bedeutet, dass in Schritt c) von der nach oben gewandten Oberfläche des Bauraums reflektierte und/oder gestreute Laserstrahlung gemessen wird. Bei der Wechselwirkung kann es sich beispielsweise auch um eine Erwärmung des Bauraums handeln, was bedeutet, dass die Laserstrahlung zumindest teilweise von dem Bauraum absorbiert wird und, erfindungsgemäß, in Schritt c) eine von dem Bauraum emittierte Wärmestrahlung gemessen wird.The interaction can be, for example, a reflection and/or a scattering on the upward-facing surface of the installation space. This means that in step c) laser radiation reflected and/or scattered by the upward-facing surface of the installation space is measured. The interaction can also involve, for example, a heating of the installation space, which means that the laser radiation is at least partially absorbed by the installation space and, according to the invention, in step c) a thermal radiation emitted by the installation space is measured.
Es ist bevorzugt, dass das Verfahren den Schritt aufweist: e) Identifizieren anhand der Abmessungen die in der nach oben gewandten Oberfläche des Bauraums angeordnete Fläche des Bauteils in einem dreidimensionalen Computermodell, das das Bauteil beinhaltet. Zudem weist das Verfahren den Schritt auf: f) Aufbringen mindestens einer Schicht des Pulvers auf die nach oben gewandte Oberfläche des Bauraums und Erweitern des Bauteils durch selektives Laserschmelzen des Pulvers mittels Laserstrahlung in jeder der Schichten anhand der Position und der in dem dreidimensionalen Computermodell identifizierten Fläche. In Schritt a) wird ein Abschnitt des Bauteils bereitgestellt und in Schritt f) ein anderer Abschnitt des Bauteils durch das selektive Laserschmelzen fertiggestellt. Durch die Verfahrensschritte e) und f) wird vorteilhaft erreicht, dass in Schritt f) genau derjenige Teil des Computermodells hergestellt wird, der von dem einen Abschnitt nicht gebildet ist, und somit die der eine Abschnitt und der Abschnitt besonders gut aufeinanderpassen. Beispielsweise können so Fertigungstoleranzen bei der Herstellung des einen Abschnitts kompensiert werden. Zudem ist es möglich das Bauteil frei von Kanten und/oder Graten herzustellen.It is preferred that the method comprises the step: e) identifying, based on the dimensions, the surface of the component arranged in the upward-facing surface of the installation space in a three-dimensional computer model that contains the component. In addition, the method has the step: f) applying at least one layer of the powder to the upward-facing surface of the installation space and expanding the component by selective laser melting of the powder using laser radiation in each of the layers based on the position and the area identified in the three-dimensional computer model . In step a) a section of the component is provided and in step f) another section of the component is completed by selective laser melting. Through method steps e) and f), it is advantageously achieved that in step f) exactly that part of the computer model is produced that is not formed by one section, and thus that one section and the section fit together particularly well. For example, manufacturing tolerances in the production of one section can be compensated for. It is also possible to produce the component free of edges and/or burrs.
Es ist bevorzugt, dass in Schritten b) und f) die gleiche Laserquelle zum Erzeugen der Laserstrahlung verwendet wird. Dadurch wird beim Rückschließen auf die Position und die Abmessungen des Bauteils und bei dem selektiven Laserschmelzen ein identisches oder zumindest sehr ähnliches Raster verwendet, so dass der eine Abschnitt und der andere Abschnitt in dem Bauteil besonders gut aufeinander passen.It is preferred that the same laser source is used to generate the laser radiation in steps b) and f). As a result, an identical or at least very similar grid is used when inferring the position and dimensions of the component and during selective laser melting, so that one section and the other section in the component fit together particularly well.
Gemäß der vorliegenden Erfindung ist die Strahlung eine Wärmestrahlung. Die Wärmestrahlung hat den Vorteil, dass sie gleichmäßig in alle Richtungen emittiert wird, so dass es eine große Flexibilität gibt, wo in der SLM-Anlage ein Detektor zum Detektieren der Wärmestrahlung angeordnet werden kann. Die Wärmestrahlung wird bevorzugt bei einer Detektionswellenlänge detektiert, die verschieden von der Wellenlänge der Laserstrahlung ist. Dadurch kann vorteilhaft vermieden werden, dass in Schritt c) die Laserstrahlung detektiert wird, was in Schritt d) das Rückschließen auf die Position und die Abmessungen des Bauteils verfälschen kann.According to the present invention, the radiation is thermal radiation. The thermal radiation has the advantage that it is emitted evenly in all directions, so there is great flexibility as to where in the SLM system a detector can be arranged to detect the thermal radiation. The thermal radiation is preferably detected at a detection wavelength that is different from the wavelength of the laser radiation. This can advantageously avoid the laser radiation being detected in step c), which can falsify the conclusions about the position and dimensions of the component in step d).
In Schritt c) wird bevorzugt derjenige Teil der Strahlung detektiert, der sich ausgehend von einem auf der nach oben gewandten Oberfläche des Bauraums angeordneten Auftreffpunkt der Laserstrahlung entgegen der Richtung der Laserstrahlung ausbreitet. Hier handelt es sich vorteilhaft um einen einfach zu justierenden Aufbau. Beispielsweise kann die Strahlung von der Laserstrahlung mittels eines Strahlteilers abgetrennt werden.In step c), that part of the radiation is preferably detected which, starting from an impact point of the laser radiation arranged on the upward-facing surface of the installation space, propagates counter to the direction of the laser radiation. The advantage here is an easy-to-adjust structure. For example, the radiation can be separated from the laser radiation using a beam splitter.
Alternativ ist bevorzugt, dass in Schritt c) derjenige Teil der Strahlung detektiert wird, der sich ausgehend von einem auf der nach oben gewandten Oberfläche des Bauraums angeordneten Auftreffpunkt der Laserstrahlung versetzt zu der Richtung der Laserstrahlung ausbreitet. Dadurch kann die Menge an der Laserstrahlung, die zusammen mit der Strahlung in Schritt c) detektiert wird und die in Schritt d) das Rückschließen auf die Position und die Abmessungen des Bauteils verfälschen kann, vorteilhaft vermindert.Alternatively, it is preferred that in step c) that part of the radiation is detected which, starting from an impact point of the laser radiation arranged on the upward-facing surface of the installation space, propagates offset from the direction of the laser radiation. As a result, the amount of laser radiation that is detected together with the radiation in step c) and which can falsify the conclusions about the position and dimensions of the component in step d) can be advantageously reduced.
Gemäß der vorliegenden Erfindung wird in Schritt d) ein Raster von in Schritt c) detektierten Intensitäten der Strahlung gebildet und Übergänge von den Bereichen zu den anderen Bereicher werden durch Identifizieren von Gradienten der Intensitäten in dem Raster bestimmt. In Abhängigkeit von den Eigenschaften des Bauteils und des Pulvers sowie in Abhängigkeit davon, wie die Strahlung beschaffen ist und wie sie detektiert wird, kann der Übergang von den Bereichen, die von dem Bauteil gebildet sind, zu den anderen Bereichen, die von dem Pulver gebildet sind, mit einer Erniedrigung der detektierten Intensität oder mit einer Erhöhung der detektierten Intensität einhergehen. Dabei ist bevorzugt, dass in Schritt c) zuerst das Raster grobmaschig abgerastert wird und nach dem Bestimmen der Übergänge in Schritt d) im Bereich der Übergänge das Raster feinmaschig abgerastert wird. Dadurch können auf die Position und die Abmessungen des Bauteils mit einer besonders hohen Genauigkeit in einer gleichzeitig kurzen Zeitdauer zurückgeschlossen werden.According to the present invention, in step d) a grid is formed from intensities of radiation detected in step c) and transitions from the regions to the other regions are determined by identifying gradients of the intensities in the grid. Depending on the properties of the component and the powder as well as depending on the nature of the radiation and how it is detected, the transition from the areas formed by the component to the other areas formed by the powder are accompanied by a reduction in the detected intensity or an increase in the detected intensity. It is preferred that in step c) the grid is first scanned with a coarse mesh and after determining the transitions in step d) the grid is scanned with a fine mesh in the area of the transitions. This allows conclusions to be drawn about the position and dimensions of the component with a particularly high level of accuracy in a short period of time.
Die Bereiche und die anderen Bereiche liegen bevorzugt in einer gleichen horizontalen Ebene, insbesondere liegen die Bereiche und die anderen Bereiche vollständig in einer gleichen horizontalen Ebene.The areas and the other areas preferably lie in the same horizontal plane, in particular the areas and the other areas lie completely in the same horizontal plane.
Die erfindungsgemäß SLM-Anlage ist eingerichtet, die Schritte des erfindungsgemäßen Verfahrens oder gemäß eines bevorzugten Verfahrens durchzuführen.The SLM system according to the invention is set up to carry out the steps of the method according to the invention or according to a preferred method.
Im Folgenden wird anhand der beigefügten schematischen Zeichnungen die Erfindung näher erläutert.
- Figur 1
- zeigt einen Querschnitt durch eine SLM-Anlage,
Figur 2- zeigt ein Bauteil und
Figur 3- zeigt das Bauteil mit einem Raster.
- Figure 1
- shows a cross section through an SLM system,
- Figure 2
- shows a component and
- Figure 3
- shows the component with a grid.
Wie es aus
Die SLM-Anlage 1 weist zudem eine Laserquelle 4 auf, die eingerichtet ist Laserstrahlung zu emittieren. Bei der Laserquelle 4 kann es sich beispielsweise um einen Nd:YAG Laser handeln. In diesem Fall kann die Laserstrahlung von der Fundamentalen des Nd:YAG Lasers gebildet sein und somit eine Wellenlänge von 1064 nm haben. Die Laserstrahlung breitet sich in einem Betrieb der SLM-Anlage 1 entlang eines Strahlengangs 5 aus. Die SLM-Anlage 1 weist einen Strahlteiler 6, einen Scanspiegel 7 und ein Linsensystem 8 auf. Wie es aus
In einem Schritt b) wird die nach oben gewandten Oberfläche 18 mit der Laserstrahlung abgerastert, wobei die Leistung und die Einwirkungsdauer der Laserstrahlung derart gewählt werden, dass das Bauteil 2 und das Pulver 3 nicht geschmolzen werden. Zudem werden die Leistung und die Einwirkungsdauer der Laserstrahlung derart gewählt, dass das Bauteil 2 und das Pulver 3 aufgewärmt werden. In dem Fall, dass es sich bei der Laserquelle 4 um einen Nd:YAG Laser handelt, kann die Leistung durch eine Variation von Lichtleistung, mit der ein Nd:YAG Kristall des Nd:YAG Laser gepumpt wird, variiert werden. Aufgrund einer Wechselwirkung der Laserstrahlung mit dem Bauraum 17 an einem Auftreffpunkt 9 der Laserstrahlung, der auf der nach oben gewandten Oberfläche 18 des Bauraums 17 angeordnet ist, wird Wärmestrahlung 10 emittiert.In a step b), the upward-facing
In einem Schritt c) wird die Wärmestrahlung detektiert. Dabei kann die Wärmestrahlung bei einer Detektionswellenlänge detektier werden, die verschieden von der Wellenlänge der Laserstrahlung ist. Bei dem Nd:YAG Laser kann die Detektionswellenlänge beispielsweise länger als 1064 nm sein. Dies kann beispielsweise mittels eines Detektors 13 oder mittels einer Kamera 14 erfolgen. Bei dem Detektor 13 ist es ausreichend, wenn er lediglich ein einzelnes Detektorelement aufweist, wie beispielsweise eine Photodiode. Die Kamera 14 hingegen weist eine zweidimensionale Matrix an Detektorelementen auf. Bei der Kamera 14 kann es sich beispielsweise um eine CMOS-Kamera oder um eine Mikrobolometerkamera handeln. Die Kamera 14 weist ein Objektiv 15 auf, das eingerichtet ist, die nach oben gewandte Oberfläche 18 des Bauraums 17 auf die zweidimensionale Matrix an den Detektorelementen abzubilden. Aufgrund des Scanspiegels 7 und des Linsensystems 8 wird es schwierig sein, die Kamera 14 senkrecht auf die nach oben gewandte Oberfläche 18 des Bauraums 17 zu richten. Die Abbildungsfehler, die aufgrund einer schrägen Ausrichtung der Kamera 14 auf die nach oben gewandte Oberfläche 18 des Bauraums 17 entstehen, können beispielsweise korrigiert werden, indem für das Objektiv 15 ein Scheimpflug Objektiv verwendet wird.In step c), the thermal radiation is detected. The thermal radiation can be detected at a detection wavelength that is different from the wavelength of the laser radiation. For example, with the Nd:YAG laser, the detection wavelength can be longer than 1064 nm. This can be done, for example, by means of a
In einem Schritt d) wird von der in Schritt c) detektierten Wärmestrahlung auf eine Position und Abmessungen des Bauteils 2 zurückgeschlossen. Dazu wird ein Raster 16 von in Schritt c) detektierten Intensitäten der Strahlung gebildet und Übergänge von den Bereichen zu den anderen Bereichen werden durch Identifizieren von Gradienten der Intensitäten in dem Raster 16 bestimmt. Wie es aus
In einem Schritt e) wird anhand der Abmessungen die in der nach oben gewandten Oberfläche 18 des Bauraums 17 angeordnete Fläche des Bauteils 2 in einem dreidimensionalen Computermodell 19 identifiziert, das das Bauteil 2 beinhaltet. Das Computermodell 19 ist in
Obwohl die Erfindung im Detail durch das bevorzugte Ausführungsbeispiel näher illustriert und beschrieben wurde, so ist die Erfindung nicht durch die offenbarten Beispiele eingeschränkt und andere Variationen können vom Fachmann hieraus abgeleitet werden, ohne den Schutzumfang der Erfindung, der durch die Ansprüche definiert wird, zu verlassen.Although the invention has been illustrated and described in detail by the preferred embodiment, the invention is not limited by the examples disclosed and other variations may be derived therefrom by those skilled in the art without departing from the scope of the invention as defined by the claims .
Claims (10)
- Method for operating an SLM system (1), having the steps:a) providing a construction space (17) in the SLM system (1), which construction space comprises a component (2) and a powder (3) adjacent thereto, wherein an upward facing surface (18) of the construction space (17) has regions that are formed by the component (2) and other regions that are formed by the powder (3);b) scanning the upward facing surface (18) with laser radiation, the power and duration of action of which are selected in such a way that the component (2) and the powder (3) are not melted;c) detecting radiation that results from interaction of the laser radiation with the construction space (17), wherein the radiation is thermal radiation (10);d) inferring a position and dimensions of the component (2) from the radiation detected in step c), wherein a grid (16) of intensities of the radiation detected in step c) is formed and transitions from the regions to the other regions are determined by means of identifying gradients of the intensities in the grid (16).
- Method according to Claim 1, having the step:
e) identifying, on the basis of the dimensions, the area of the component (2) arranged in the upward facing surface (18) of the construction space (17) in a three-dimensional computer model (19) which includes the component (2). - Method according to Claim 2, having the step:
f) applying at least one layer of the powder (3) to the upward facing surface (18) of the construction space (17) and extending the component (2) by means of selective laser melting of the powder (3) using laser radiation in each of the layers on the basis of the position and the area identified in the three-dimensional computer model (19) . - Method according to Claim 3, wherein the same laser source (4) is used for generating the laser radiation in steps b) and f).
- Method according to one of Claims 1 to 4, wherein the thermal radiation (10) is detected at a detection wavelength which is different from the wavelength of the laser radiation.
- Method according to one of Claims 1 to 5, wherein, in step c), that part of the radiation which, emanating from a point of incidence (9) of the laser radiation arranged on the upward facing surface (18) of the construction space (17), propagates counter to the direction of the laser radiation is detected.
- Method according to one of Claims 1 to 6, wherein, in step c), that part of the radiation which, emanating from a point of incidence (9) of the laser radiation arranged on the upward facing surface (18) of the construction space (17), propagates offset to the direction of the laser radiation is detected.
- Method according to one of Claims 1 to 7, wherein, in step c), first the grid (16) is scanned with a coarse mesh and, after determining the transitions in step d), the grid (16) is scanned with a fine mesh in the region of the transitions.
- Method according to one of Claims 1 to 8, wherein the regions and the other regions lie in a same horizontal plane, in particular the regions and the other regions lie completely in a same horizontal plane.
- SLM system (1) which is configured to carry out the steps of the method according to one of Claims 1 to 9.
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